Panel Mounting System

ABSTRACT

A panel mounting system for mounting a panel (particularly a solar panel) to a structure. A load element connects a panel retainer to the roof structure and plastically deforms to a deformed configuration upon application of a predetermined threshold load to the load element. The load element typically has a cranked initial condition and elongates during plastic deformation. The mounting system prevents roof damage due to wind loading on the panels.

The present invention relates to a panel mounting system and particularly to a panel mounting system suitable for mounting structural, decorative or functional panels to structures such as building walls or roofs.

The system is particularly suitable for mounting panels to fragile structures such as roof structures formed of metal skin panels. Such fragile structures require mounting fixings which do not damage the structural integrity of the structure (such as the metal roof skin). It is important, for example that in fixing the system to a fragile structure that the weatherproofing of the structure is not compromised.

An improved system has now been devised.

According to a first aspect, the invention provides a panel mounting system for mounting a panel to a structure, the panel mounting system comprising a panel retaining device and a load element for connecting the panel retaining device to the structure, the load element having an initial configuration and being arranged to plastically deform to a second configuration upon application of a predetermined threshold load to the load element.

The facility for the load element to plastically deform to a second configuration when the threshold limit is reached or exceeded can be important. When the threshold loading is reached, the additional load above the threshold limit is taken up in plastic deformation of the load element, rather than being transferred directly to any mechanical fixings securing the mounting system to the structure. This can prevent damage to the structure from excessive loading. This may be particularly important where the structure is fragile such as for thin metallic skin structures such as profiled roofs.

Detrimental loading can occur, for example due to wind loading, particularly gusting where aerofoil effects can cause panels to be lifted upwardly or outwardly from the structures to which they are secured.

It is preferred that the load element comprises an elongate element and the load element plastically deforms upon application of the predetermined load to elongate in the longitudinal direction.

Beneficially, the load element comprises opposed end portions extending in a generally common direction and a cranked portion at a position intermediate the opposed ends. The cranked portion is generally a v shaped or kinked portion, and preferably extends transversely to the longitudinal direction of the load element.

In a preferred embodiment the load element comprises an elongate strut, preferably a metal strut.

It is preferred that the elongate strut is provided at a proximal end with means for securing to the structure and at its distal end secured to the panel retaining element.

In certain embodiments it is preferred that the panel retaining element comprises a panel retaining bracket. The bracket may extend about the entire periphery of the panel or alternatively retain the panel at certain specific points or locations around the periphery of the panel.

In certain embodiments, it may be preferred that the panel retaining element is configured to secure panels in adjacent side by side relationship.

Beneficially, the load element is arranged to bear the load of the panel (in compression).

It is desirable that the load element is arranged to space the panel from the structure.

In certain embodiments, it is preferred that when the load element reconfigures from its initial configuration to its second configuration, the external appearance of the system gives a visual indication that the reconfiguration has taken place. This provides that, when the load element has deformed due to an applied load greater than the threshold, there is a readily visible indication that the excess load has occurred.

Desirably, the system is provided with a two or more part casing for the load element the casing parts moving with respect to one another to vary the external appearance of the system as the load element plastically deforms. The casing may be provided with an indicator that only becomes visible when the casing parts have moved as a result of deformation of the load element.

In certain embodiments, it is preferred that the load element is secured to a base.

The base may beneficially be provided with means (such as mechanical fixings) for securing to the structure.

In an alternative aspect, the invention provides a method of mounting a panel to a structure the method comprising securing the panel to a panel retaining device which is provided with a load element for connecting the panel retaining device to the structure, the load element having an initial configuration and being arranged to plastically deform to a second configuration upon application of a predetermined threshold load to the load element.

According to an alternative aspect, the invention provides a system for supporting a structural load, the system comprising a load element having an initial configuration under a first loading regime in which a structural load is applied by to the load element in either tension or compression, and being arranged to plastically deform to a second configuration upon application of a predetermined threshold load to the load element.

The invention will now be further described by way of example only, and with reference to the accompanying drawings, in which;

FIG. 1 is a schematic explanatory view of a panel mounting system in accordance with the invention;

FIG. 2A is a schematic explanatory view of a portion of the system of FIG. 1;

FIG. 2B is a detail view of a part of FIG. 2A;

FIG. 3 is a schematic view of an alternative embodiment of panel mounting system in accordance with the invention;

FIG. 4 is a is a schematic explanatory view of an alternative embodiment of panel mounting system in accordance with the invention.

Referring to the drawings, there is shown a panel mounting system 1 for mounting a panel 2 to a structure 3. In the embodiment primarily described, the panel 2 comprises a solar panel 2 which is mounted on top of a flat or profiled skin roof 3. The invention is however applicable in respect of mounting of other panels to supporting structures and indeed to other situations in which a structural load needs to be supported but excess loading avoided.

The panel mounting system comprises a mounting structure 4 which may be in the form of a post, which is secured to the roof structure 3 and a panel retaining arrangement which may be in the form of a bracket 5 for securing or seating the panel edge 2. The panel retaining bracket 5 may be in the form of a rectangular frame that extends around the entire periphery of the panel, or alternatively may engage portions of the frame at the location of the mounting posts only. Fixings may be provided to mechanically fix the panels 2 with respect to the panel mounting system. Such fixings may be for example screws. In the embodiment shown on FIG. 1, a single panel 2 only is shown mounted to the structure, with the panel mounting system having mounting posts provided at the four corners of the panel. In alternative embodiments a double bracket fixing may be provided for mounting panels adjacent one another, in side by side relationship in a common plane, such as for example, as shown in FIG. 3.

Referring now to FIGS. 2A and 2B, there is shown in detail a preferred embodiment of panel mounting system in accordance with the invention. This arrangement is particularly useful for mounting a solar panel 2 on a delicate structure such as a profiled metal skin roof or wall structure. The panel mounting system of FIG. 2 includes a base plate 6 which is suitable for securing to a structural metal skin using screw fixings which pass through pre-formed holes in fixing points 7 defined in the base 6. The base 6 has a raised portion 6 a leading to a central plateau portion 6 b which has a central circular aperture 6 c having a downturned edge.

The panel retaining bracket 5 is secured to the base by a central elongate support strut 9 which forms a load element in accordance with the invention. The support strut 9 is secured at its lower end to the base 6. The lower end of the strut 9 extends through the aperture 6 c in base 6 and is provided with a ferrule nut 10. A spring spreader washer 11 is provided to transfer force from the ferrule nut 10 to the underside of the base 6.

The upper end of the support strut 9 is threaded and received in a threaded element 12, the upper end of which is also threaded to receive the threaded shaft of bracket fixing bolt 13. The bracket fixing bolt 13 passes through an aperture in the lower limb of the bracket 5. In this way the bracket 5 is tied to the base 6 by the strut 9. The upper and lower portions of the strut 9 extend in a common direction and indeed are preferably aligned along a substantially common axis. Intermediate the ends the strut 9 is provided with a cranked portion 9 a in the form of a v shaped portion extending transversely to the common longitudinal direction of the upper and lower portions of the strut 9. The strut 9 is so formed to take the weight (in compression loading) of the supported panel without plastically deforming under normal load conditions.

Similarly, the strut 9 is formed to withstand plastic deformation under tensile loading of the strut up to a threshold or limit value and subsequently to elongate in plastic deformation when the threshold limit is reached or exceeded. In this way if the threshold tensile load is reached, the strut elongates, deforming plastically. The v shaped cranked portion 9 a of the strut achieves this conveniently, and also provides a form of spring or resilience over a range of elasticity for loads (tensile or compressive) up to the threshold limit.

This facility for the cranked strut 9 to elongate in plastic deformation when the threshold limit is reached or exceeded can be important in two respects. Firstly when the threshold loading is reached in tensile loading, the additional load above the threshold limit is taken up in plastic deformation due to elongation of the strut 9, rather than being transferred directly to the mechanical fixings securing the base 6 to the structure 3. This can prevent damage to the structure 3 from excessive upward loading. This may be particularly important where the structure is fragile such as for thin metallic skin structures such as profiled roofs.

Secondly when the strut has elongated due to an applied upward load greater than the threshold, there is a readily visible indication that the excess load has occurred. In the embodiment of FIGS. 2A and 2B the mounting post 4 has a casing 15 provided in two parts, an upper part 15 a which is secured to the upper portion of the ranked strut 9, and a lower part 15 b which is secured to the base 6. Upon elongation of the cranked strut 9 the casings separate either telescopically, in which case for example it is possible to reveal a coloured indicator band provided on the telescopically inner casing, or simply to expose a gap between the upper and lower casing parts 15 a 15 b.

Such loading can arise for example due to wind loading particularly gusting where aerofoil effects can cause panels to be lifted upwardly or outwardly from the structures to which they are secured.

The invention can also be useful in situations where tensile loading of structural fixings can occur and there is a desire to keep the loading effect on the building below a minimum. For example where tension cables are used to secure masts or other upright structures, the ends of the ties can be secured using a mounting system in accordance with the invention.

In certain embodiments the base plate need not be provided and the lower end of the cranked strut 9 may be secured directly to the structure (for example directly through a metal skin roof panel).

In other embodiments the load element (strut 9 for example) or the base may be secured to a roof skin by means other than screw fixings. For example clamp fixings may be used to secure to standing seams of a metal skin roof structure.

In the arrangement of FIG. 4 the mounting structure is once again in the form of a post 14, which is secured to the roof structure 13. In this embodiment, the panel retaining arrangement 15 comprises pinch clamps 18 for securing or seating the panel edge 2. The pinch clamps 18 are slidably retained in a runner rail 17, which is itself secured to a transversely extending frame rail 16. The strut 19 extends upwardly from its cranked part 19 a, through frame rail 16 to secure on the base of the runner rail 17. 

1. A panel mounting system for mounting a panel to a structure, the panel mounting system comprising: a panel retaining arrangement; and a load element for connecting the panel retaining arrangement to a structure; wherein the load element has an initial configuration and is arranged to plastically deform to a second configuration upon application of a predetermined threshold load to the load element.
 2. A panel mounting system according to claim 1, wherein the load element comprises an elongate element, and the load element plastically deforms upon application of the predetermined load to elongate in the longitudinal direction.
 3. A panel mounting system according to claim 1, wherein the load element comprises opposed end portions extending in a generally common direction, and a cranked portion at a position intermediate the opposed ends.
 4. A panel mounting system according to claim 1, wherein the load element comprises an elongate strut.
 5. A panel mounting system according to claim 4, wherein the elongate strut is provided at a proximal end with means for securing to a structure and at its distal end secured to the panel retaining arrangement.
 6. A panel mounting system according to claim 1, wherein the panel retaining arrangement comprises a panel retaining bracket or clamp.
 7. A panel mounting system according to claim 6, wherein the panel retaining bracket or clamp is movable along a securing frame element.
 8. A panel mounting system according to claim 1, wherein the panel retaining element is configured to secure panels in adjacent side by side relationship.
 9. A panel mounting system according to claim 1, wherein the load element is arranged to bear the load of a panel.
 10. A panel mounting system according to claim 1, wherein the load element is arranged to space a panel from a structure.
 11. A panel mounting system according to claim 1, wherein when the load element reconfigures from its initial configuration to its second configuration, the external appearance of the system gives a visual indication that the reconfiguration has taken place.
 12. A panel mounting system according to claim 11, wherein the system is provided with a plural part casing for the load element, the casing parts moving with respect to one another to vary the external appearance of the system as the load element plastically deforms.
 13. A panel mounting system according to claim 1, wherein the load element is secured to a base.
 14. A panel mounting system according to claim 13, wherein the base is provided with means for securing to a structure.
 15. A method of mounting a panel to a structure, the method comprising: securing a panel to a panel retaining arrangement; connecting the panel retaining device to a structure with a load element having an initial configuration; and plastically deforming the load element to a second configuration upon application of a predetermined threshold load to the load element.
 16. A method of mounting a solar panel at a position spaced above a structural roof skin, the method comprising: securing a panel to a panel retaining arrangement; connecting the panel retaining arrangement to a roof skin with a load element having an initial configuration; and plastically deforming the load element to a second configuration upon application of a predetermined threshold load to the load element.
 17. A system for supporting a structural load, the system comprising a load element having an initial configuration under a first loading regime and being arranged to plastically deform to a second configuration upon application of a predetermined threshold load to the load element.
 18. A panel mounting system according to claim 7, wherein the securing frame element comprises an element selected from the group consisting of a channel, rail and runner.
 19. A panel mounting system according to claim 9, wherein the load element is arranged to bear the load of a panel in compression. 